41AE/Te Automatic Transaxle: Disassembly

NOTE: If transaxle is being overhauled (clutch and/or seal replacement) or replaced, it is necessary to perform the PCM/TCM Quick Learn Procedure. (Refer to STANDARD PROCEDURE - QUICK LEARN PROCEDURE )

NOTE: This procedure does not include final drive (differential) disassembly.

Fig 1: Removing Power Transfer Unit Lower Bolts

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Fig 2: Removing Oil Pan-To-Transaxle Collar

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1. Remove input and output speed sensors.
2. Remove three (3) solenoid/pressure switch assembly-to-case bolts.
   Fig 3: Removing Torque Converter Dust Shield

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3. Remove solenoid/pressure switch assembly and gasket (Fig 4).
   Fig 4: Identifying Solenoid/Pressure Switch Assembly And Gasket

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4. Remove oil pan-to-case bolts (Fig 5).
   Fig 5: Removing Oil Pan Bolts

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5. Remove oil pan (Fig 6).
   Fig 6: Removing Oil Pan

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6. Remove oil filter (Fig 7).
7. Turn manual valve fully clock-wise to get park rod into position for removal.
8. Remove valve body-to-case bolts (Fig 8).
   CAUTION: Do not handle the valve body assembly from the manual valve. Damage can result.
   Fig 7: Removing Oil Filter

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   Fig 8: Removing Valve Body Attaching Bolts

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9. Using a screwdriver, push park rod rollers away from guide bracket (Fig 9) and remove valve body assembly (Fig 10).
   Fig 9: Identifying Push Park Rod Rollers From Guide Bracket

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   Fig 10: Removing Valve Body

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   NOTE: Depending on engine application, some accumulators will have two springs and others will have one spring. The springs are color-coded according to application and year. When disassembling, mark accumulator spring location to ease assembly.
10. Remove underdrive and overdrive accumulators (Fig 11) (Fig 12) (Fig 13).
    Fig 11: Removing Underdrive And Overdrive Accumulators

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    Fig 12: Removing Accumulator (Underdrive)

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    Fig 13: Removing Accumulator (Overdrive)

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11. Remove low/reverse accumulator snap ring (Fig 14).
    Fig 14: Removing Low/Reverse Accumulator Snap Ring

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12. Remove low/reverse accumulator plug (Fig 15).
    Fig 15: Removing Low/Reverse Accumulator Plug (Cover)

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13. Remove low/reverse accumulator piston using petrolatum and a suitable tool (Fig 16).
    Fig 16: Removing Low/Reverse Accumulator Piston

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14. Remove low/reverse accumulator (Fig 17).
    Fig 17: Removing Low/Reverse Accumulator

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15. Measure input shaft end play. Place transaxle so input shaft is vertical. Set up end play set and dial indicator as shown in (Fig 18). Input shaft end play should be within 0.13-0.64 mm (0.005-0.025 in.)  If outside of this range, a #4 thrust plate change is required. Record indicator reading for reference upon reassembly.
    Fig 18: Measuring Input Shaft End Play Using End Play Set 8266

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16. Remove oil pump-to-case bolts (Fig 19).
    Fig 19: Removing Pump Attaching Bolts

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    CAUTION: Be sure input speed sensor is removed before removing oil pump.
17. Install pullers Tool C-3752 as shown in (Fig 20).
    Fig 20: Installing Tool C-3752

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18. Remove oil pump assembly (Fig 21) (Fig 22).
    Fig 21: Removing Oil Pump

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    Fig 22: Identifying Oil Pump

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19. Remove oil pump gasket (Fig 23).
    CAUTION: If transaxle failure has occurred, the cooler bypass valve must be replaced. Do not re-use or attempt to clean valve.
20. Remove cooler bypass valve (Fig 24).
21. Remove #1 needle bearing (Fig 25).
    Fig 23: Removing Oil Pump Gasket

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    Fig 24: Removing Bypass Valve

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    Fig 25: Removing Caged Needle Bearing

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22. Remove input clutch assembly (Fig 26).
    Fig 26: Removing Input Clutch Assembly

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23. Remove #4 thrust plate (Fig 27).
    Fig 27: Removing Thrust Plate

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    Fig 28: Removing Front Sun Gear Assembly

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24. Remove front carrier/rear annulus assembly and #6 needle bearing (Fig 29).
    Fig 29: Removing Front Carrier And Rear Annulus Assembly

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25. Remove rear sun gear and #7 needle bearing (Fig 30).
    NOTE: The number 7 needle bearing has three antireversal tabs and is common with the number five and number two position. The orientation should allow the bearing to seat flat against the rear sun gear (Fig 31). A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
    Fig 30: Removing Rear Sun Gear

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    Fig 31: Removing Number 7 Bearing

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26. Setup tool 5058 as shown in (Fig 32). Compress 2/4 clutch return spring (just enough to remove snap ring) and remove snap ring.
    NOTE: Verify that Tool 5058 is centered properly over the 2/4 clutch retainer before compressing. If necessary, fasten the 5058 bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.
    Fig 32: Removing 2/4 Clutch Retainer Snap Ring

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27. Remove 2/4 clutch retainer (Fig 33).
    Fig 33: Removing 2/4 Clutch Retainer

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28. Remove 2/4 clutch return spring (Fig 34).
    Fig 34: Removing 2/4 Clutch Return Spring

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29. Remove 2/4 clutch pack (Fig 35). Tag 2/4 clutch pack for reassembly identification. 
    Fig 35: Removing 2/4 Clutch Pack

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30. Remmove tapered snap ring (Fig 36).
    Fig 36: Removing Tapered Snap Ring

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31. Remove low/reverse reaction plate (Fig 37).
    Fig 37: Removing Low/Reverse Reaction Plate

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32. Remove one low/reverse clutch disc (Fig 38).
    Fig 38: Removing One Disc

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33. Remove low/reverse reaction plate snap ring (Fig 39).
    Fig 39: Removing Low/Reverse Reaction Plate Snap Ring

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34. Remove low/reverse clutch pack (Fig 40).
    Fig 40: Removing Low/Reverse Clutch Pack

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35. Remove transfer gear cover-to-case bolts (Fig 41).
    Fig 41: Removing Rear Cover Bolts

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36. Remove transfer gear cover (Fig 42).
    Fig 42: Removing Rear Cover

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37. Using Tool 6259, remove transfer shaft gear-to-shaft nut and coned washer (Fig 43) (Fig 44).
    Fig 43: Removing Transfer Shaft Gear Nut

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    Fig 44: Removing Transfer Shaft Gear Nut And Coned Washer

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38. Using tool L-4407A, remove transfer shaft gear (Fig 45).
    Fig 45: Removing Transfer Shaft Gear Sing Tool L-4407A

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39. Remove transfer gear shim (select) (Fig 46).
    Fig 46: Removing Transfer Shaft Gear And (Select) Shim

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40. Remove bearing cup retainer (Fig 47).
    Fig 47: Removing Bearing Cup Retainer

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41. Remove transfer gear bearing cone using setup shown in (Fig 48).
    Fig 48: Removing Transfer Gear Bearing Cone

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42. Remove transfer shaft bearing cup from retainer using Tool 6062 (Fig 49).
    Fig 49: Removing Transfer Shaft Bearing Cup

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43. Using Tool 6051, remove transfer shaft bearing snap ring (Fig 50).
    Fig 50: Removing Transfer Shaft Bearing Snap Ring

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44. Using tool 5049A, remove transfer shaft from transaxle (Fig 51).
    Fig 51: Removing Transfer Shaft

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45. Slip bearing cup retainer and oil baffle off of shaft (Fig 52)
    Fig 52: Removing Bearing Cup

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46. Using tool P-334, press transfer shaft bearing cone off of shaft (Fig 53).
    Fig 53: Removing Transfer Shaft Bearing Cone

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47. Bend output gear retaining strap ears flat to allow bolt removal.
48. Remove output shaft stirrup strap bolts (Fig 54).
    Fig 54: Removing Strap Bolts

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49. Remove stirrup and strap (Fig 55).
    Fig 55: Removing Stirrup Strap

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50. Using Tool 6259 (Fig 56), remove output shaft gear-to-shaft bolt and washer (Fig 57).
    Fig 56: Removing Output Gear Bolt Using Tool 6259

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    Fig 57: Installing Output Gear Bolt And Washer

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51. Using Tool L4407A, and button 6055, remove output gear from shaft (Fig 58).
    Fig 58: Removing Output Gear

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52. Remove output gear bearing shim (select) (Fig 59).
    Fig 59: Removing Output Gear And (Select) Shim

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53. Using setup as shown in (Fig 60), remove output gear bearing cone.
    Fig 60: Removing Bearing Cone

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54. Remove rear carrier assembly from transaxle (Fig 61).
    Fig 61: Removing Rear Carrier Assembly

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55. Remove rear carrier assembly bearing cone using setup shown in (Fig 62).
    Fig 62: Removing Rear Carrier Bearing Cone

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56. Install low/reverse spring compressor tool as shown in (Fig 63) (Fig 64).
    Fig 63: Installing Low/Reverse Spring Compressor Tool

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    Fig 64: Installling Compressor Tool In Use

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57. Compress low/reverse piston return spring and remove snap ring (Fig 65).
    Fig 65: Removing Snap Ring

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58. Remove low/reverse spring compressor tool and low reverse piston return spring (Fig 66).
    Fig 66: Removing Low/Reverse Piston Return Spring

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59. Using a suitable punch drive out park guide bracket pivot shaft plug (Fig 67).
    Fig 67: Removing Anchor Shaft And Plug

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60. Using ordinary pliers, remove pivot shaft and guide bracket assembly (Fig 68).
61. Inspect guide bracket components for excessive wear and replace if necessary (Fig 69).
    Fig 68: Installing Pivot Shaft And Guide Bracket

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    Fig 69: Removing Guide Bracket

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62. Remove low/reverse clutch piston (Fig 70).
    Fig 70: Removing Low/Reverse Clutch Piston

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63. Remove low/reverse piston retainer-to-case screws (Fig 71).
    Fig 71: Removing Piston Retainer Attaching Screws

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64. Remove low/reverse piston retainer (Fig 72).
    Fig 72: Removing Piston Retainer

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65. Remove low/reverse piston retainer-to-case gasket (Fig 73).
    Fig 73: Removing Piston Retainer Gasket

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66. Using a hammer and suitable drift, drive out inner output bearing cup (Fig 74).
    Fig 74: Removing Output Bearing Inner Cup

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67. Using tool 6062, remove outer output bearing cup (Fig 75).
    Fig 75: Removing Output Bearing Outer Cup

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